WO2009086056A2 - Multilayer flashing tape - Google Patents

Multilayer flashing tape Download PDF

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Publication number
WO2009086056A2
WO2009086056A2 PCT/US2008/087601 US2008087601W WO2009086056A2 WO 2009086056 A2 WO2009086056 A2 WO 2009086056A2 US 2008087601 W US2008087601 W US 2008087601W WO 2009086056 A2 WO2009086056 A2 WO 2009086056A2
Authority
WO
WIPO (PCT)
Prior art keywords
multilayer film
skin
layer
core layer
film according
Prior art date
Application number
PCT/US2008/087601
Other languages
French (fr)
Other versions
WO2009086056A3 (en
Inventor
Thomas B. Galush
George J. Clements
John J. Erickson
Gerald S. Deeb
Original Assignee
3M Innovative Properties Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Priority to US12/808,820 priority Critical patent/US20100307658A1/en
Priority to JP2010539855A priority patent/JP5694777B2/en
Priority to CN2008801244044A priority patent/CN101909884A/en
Priority to EP08869013A priority patent/EP2231400B1/en
Publication of WO2009086056A2 publication Critical patent/WO2009086056A2/en
Publication of WO2009086056A3 publication Critical patent/WO2009086056A3/en
Priority to US13/690,459 priority patent/US20130139953A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/12Layered products comprising a layer of natural or synthetic rubber comprising natural rubber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/18Layered products comprising a layer of natural or synthetic rubber comprising butyl or halobutyl rubber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/28Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/28Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/286Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polysulphones; polysulfides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/34Layered products comprising a layer of synthetic resin comprising polyamides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/40Layered products comprising a layer of synthetic resin comprising polyurethanes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/033 layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/24All layers being polymeric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/20Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/21Anti-static
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51Elastic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54Yield strength; Tensile strength
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/71Resistive to light or to UV
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/726Permeability to liquids, absorption
    • B32B2307/7265Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/746Slipping, anti-blocking, low friction
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2405/00Adhesive articles, e.g. adhesive tapes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00Buildings or parts thereof
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495Thickness [relative or absolute]

Definitions

  • the present disclosure relates generally to a flashing tape used in construction applications to seal out moisture, and methods of using the same.
  • the flashing tapes comprise a viscoelastic core and at least one elastomeric skin layer.
  • the present disclosure is directed to a multi-layer flashing tape, the tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer.
  • the second elastomeric skin layer may be eliminated such that the core layer of the construction is attached to a substrate with the single skin layer outwardly exposed.
  • a PSA pressure sensitive adhesive
  • a PSA may be applied to at least a portion of the core layer to assist in the attachment of the film to a substrate.
  • a multi-layer flashing tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and optionally a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer; and
  • the present disclosure is directed to a method of sealing an intersection between buildings surfaces, for example, a roof-wall joint, a roof valley, a roof peak, etc., wherein the method comprises the steps of:
  • a multi-layer flashing tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and optionally a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer; and
  • viscoelastic means the characteristic of a material that has both viscous and elastic mechanical properties. Viscous materials tend to deform or flow under an applied stress. Elastic materials tend to recover or rebound after an applied stress is removed. As used to describe the materials herein, the term “viscoelastic” refers to materials having a G' Storage Modulus of about 30,000 Pa to about 500,000 Pa.
  • the term “elastomeric” means the characteristic of a material that is both flexible and elastic. These materials tend to recover or rebound after an applied stress is removed. As used to describe the materials herein, the term “elastomeric” refers to materials having an elastic recovery of greater than about 70%.
  • the term “fenestration” means any opening in a buildings envelope for the placement of windows, doors, skylights, ventilation ducts, chimneys and the like.
  • the term “thermoplastic material” means a material which softens or can be fused together when heated and which will harden again upon cooling. This process can be repeated many times with minimal degradation of physical or material properties.
  • PSA pressure sensitive adhesive
  • FIGURE illustrates a multilayer film according to some embodiments of the present disclosure.
  • the present disclosure is directed to a self-sealing, multilayered film that may be used in conjunction with a pressure-sensitive adhesive (PSA) as part of a flashing tape designed for sealing around mechanical fasteners such as nails to prevent water penetration in a building structure.
  • the multi-layered film structure comprises a viscoelastic core layer having a first major surface opposite a second major surface, a first elastomeric skin layer bonded to the first major surface of the core layer, and an optional second elastomeric skin layer bonded to the second major surface of the core layer.
  • the multilayered films of the current disclosure advantageously provide excellent sealing properties in a material having a thin construction relative to known materials.
  • Typical flashing materials utilize a relatively thick layer of butyl rubber or asphaltic adhesive applied to a carrier film layer.
  • Such constructions have been known to fail at low temperatures and additionally add substantial thickness when applied to a fenestration joint.
  • flashing materials are too thick, windows, trim, siding, j-channel or other structures which must be installed into or adjacent to the fenestrations may not fit properly.
  • the multilayered film flashing materials described herein provide excellent sealing properties while having a total thickness of no greater than about 410 microns (e.g., no greater than about 380 microns) exclusive of the PSA adhesive.
  • the flashing materials described herein protect structures from moisture penetration, even when punctured by nails, staples or other materials.
  • the core layer has a thickness of no greater than about 127 microns. In a further embodiment, the core layer has a thickness that is no greater than about 80 microns, and in yet a further embodiment, the core layer thickness is no greater than about 55 microns.
  • the core to skin ratio of the multilayered film is at least 0.2, e.g., at least about 0.5. In some embodiments, the core to skin ratio of the multilayered film is no greater than 5, e.g., no greater than 2.5. In some embodiments, the core to skin ratio of the multilayered film ranges from about 0.2 to about 5. In other embodiments, the core to skin ratio of the multilayered film is ranges from about 0.5 to about 2.5.
  • films constructed with skins that had higher elastic recovery e.g., 96%) tended to perform better with cores that had a higher elasticity as shown by a higher G' Storage Modulus.
  • films constructed with skins that had lower elastic recovery e.g., 73 to 75%) tended to work better with cores that were more deformable as shown by a lower G' Storage Modulus. It has generally been found that films with a high elastic recovery are harder to deform than films with a lower elastic recovery.
  • the core layer may be made from a variety of viscoelastic materials.
  • materials which may be used for the core layer include but are not limited to tackif ⁇ ed natural rubbers; synthetic rubbers such as butyl rubber; and tackif ⁇ ed linear and radial styrene block copolymers, such as styrene-butadiene, styrene-ethylene/butylene and styrene-isoprene; polyurethanes; polyvinyl ethers; acrylics, especially those having long chain alkyl groups; poly-alpha- olef ⁇ ns; asphaltics and silicones.
  • compositions that is useful as a PSA for box sealing tape comprising block or random styrene elastomers and tackif ⁇ ers is used.
  • the core layer can also be made from a block or random styrene elastomer copolymer resin without tackif ⁇ er.
  • the viscoelastic core layer has a storage modulus of from 30,000 Pa to 500,000 Pa. In some embodiments, the core has a storage modulus of no greater than 100,000 Pa, e.g., no greater than 75,000 Pa. In some embodiments, the core has a storage modulus at least 200,000 Pa, e.g., at least 400,000 Pa. In some embodiments, the viscoelastic core layer has a Glass Transition Temperature of from 200 K to 260 K.
  • thermoplastic film forming polymers examples include thermoplastic film forming polymers.
  • Exemplary thermoplastic film forming polymers either alone or in combination include but are not limited to polyolefms (linear or branched), olefin block copolymers, polyamides, polystyrenes, polystyrene- butadienes, nylons, polyesters, polyester copolymers, polyurethanes, polysulfones, polyvinylidene chloride, styrene-maleic anhydride copolymers, styrene acrylonitrile copolymers, ionomers based on sodium or zinc salts of ethylene methacrylic acid, polymethylmethacrylates, cellulosics, fluoroplastics, acrylic polymers and copolymers, polycarbonates, polyacrylonitriles, ethylene -vinyl acetate copolymers, and mixtures thereof.
  • At least one skin layer in some embodiments both skin layers, have a tensile modulus of no greater than 8 MPa, e.g., no greater than 5 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have a tensile modulus of between 10 and 20 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have a tensile modulus of at least 30 MPa, e.g., at least 40 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have an elastic recovery of at least 70%, in some embodiments, at least 90%, or even at least 95%.
  • the construction includes a core layer having a storage modulus at least 200,000 Pa, e.g., at least 400,000 Pa, and at least one skin layer (in some embodiments, both skin layers) having a tensile modulus of no greater than 8 MPa, e.g., no greater than 5 MPa.
  • the construction includes a core layer having a storage modulus no greater than 100,000 Pa, e.g., no greater than 75,000 Pa, and at least one skin layer (in some embodiments, both skin layers) having a tensile modulus of at least 30 MPa, e.g., at least 40 MPa.
  • a PSA layer may be applied to at least a portion of the exposed surface of one or both skin layers, or to the underside of the core layer, in order to facilitate attachment of the core or skin layer to the substrate or joint to be protected.
  • Suitable materials which may be utilized for the PSA layer include, but are not limited to tackif ⁇ ed natural rubbers; synthetic rubbers such as butyl rubber; and tackif ⁇ ed linear and radial styrene block copolymers, such as styrene -butadiene, styrene-ethylene/butylene and styrene- isoprene; polyurethanes; polyvinyl ethers; acrylics, especially those having long chain alkyl groups; poly-alpha-olef ⁇ ns; asphaltics and silicones.
  • an acrylic PSA that offers low temperature adhesion performance is used.
  • the PSA layer should have sufficient adhesive strength to adhere the flashing material to a building structure comprising materials such as wood, polyvinyl chloride, rigid polystyrene foamboard, polymer materials used in housewrap applications, concrete block, poured concrete, building paper, and the like.
  • the PSA layer may be applied with full or partial coverage on one or both of the skin layers, or the core layer in the embodiment where only one skin layer is used.
  • the PSA layer may be applied to the multilayer film structure by extrusion, lamination or other conventionally known methods. A release liner may be applied over the adhesive to protect the adhesive until the multilayer flashing film is ready for use.
  • the core layer and/or the skin layers may also contain other components such as pigments, fillers, ultraviolet absorbing agents, light stabilizers (e.g., hindered amine light stabilizers), slip agents, antiblocking agents, antistatic agents, processing aids, and carrier resins for additives, all of which are familiar to those skilled in the art. These additives are preferably chosen so as not to interfere with the desired performance and physical, chemical and adhesive properties of the film construction.
  • Multilayer film 10 includes core layer 20 and first skin layer 31 on one major surface of the core layer.
  • second skin layer 32 is located on the opposite major surface of core layer 20.
  • a tape e.g., a flashing tape, can be prepared by including optional adhesive layer 40, which is shown adjacent second skin layer 32 in the Figure.
  • the multilayer films of the present disclosure may be formed by any convenient layer forming process such as coating, lamination, co-extruding layers or stepwise extrusion of layers. Co-extrusion per se is well-known. The individual layers are typically coextruded through a specialized feed block or a specialized die that will bring the diverse materials into contact while forming the film.
  • Co-extrusion may be carried out with multilayer feed blocks or dies, for example, a three-layer feed block (fed to a die) or a three-layer die such as those made by Cloeren Co., Orange, Texas.
  • multilayer feed blocks or dies for example, a three-layer feed block (fed to a die) or a three-layer die such as those made by Cloeren Co., Orange, Texas.
  • streams of materials flowing out of extruders at different viscosities are separately introduced into the feedblock and converge to form a film.
  • the feed block and die used are typically heated to facilitate polymer flow and layer adhesion.
  • the temperature of the die depends on the polymers used. Whether the film is prepared by coating, lamination, sequential extrusion, co-extrusion, or a combination thereof, the film formed and its layers will preferably have substantially uniform thicknesses across the film.
  • Flashing materials made with the multi-layer films as described herein may be wound onto cores and packaged in roll-form, in any size that is convenient for covering various fenestration joints or other related surfaces. In use, the flashing material is installed onto various building surfaces so that a path for draining incidental water is provided.
  • AAMA 711 Annex 1 is a modified version of ASTM E331. Note: The test method requires 3 sample boards run simultaneously at an air pressure of 5 inches of water (1.25 kPa) and 3 sample boards run simultaneously at an air pressure of 1.57 inches of water (0.39 kPa). For most of these examples, 4 sample boards (two at a time) at 5 inches of water pressure (1.25 kPa), were tested. The data is based on initial conditions only - no thermal cycling was performed. For some samples that performed very poorly, only two panels were tested.
  • ICC International Code Council
  • Elastic Recovery was measured using a modified version of ASTM D5459 on 3 specimens taken from the machine direction at a width of 13 mm (0.5 inch).
  • Tensile Modulus and 1% Secant Modulus were measured using a modified version of ASTM D882 on 3 specimens taken from the machine direction at a width of 13 mm (0.5 in.).
  • Shear Storage Modulus (G') was measured on core samples C-I to C-4 using an RDA II rheometer from Rheometrics, Inc. at 1 Hz, 1% strain, at 21 0 C (70 0 F), 49% relative humidity, using 25 mm diameter parallel plates at 500 g compression.
  • Shear Storage Modulus (G') for core sample C-5 was measured using an ARES rheometer from TA Instruments. The measurements were taken using 25 mm diameter parallel plates in dynamic mode with approximately 45O g compressive force at 1 Hz, 1% Strain, at approximately 24 0 C (74 0 F) [0047] The glass transition temperature (Tg) was calculated using the Fox equation. [0048] Core Materials.
  • Core 1 was a Styrene-Ethylene/Butylene-Styrene Polymer (KRATON G1657; from Kraton Polymers). Core 1 had a Tg of 215 K and a storage modulus of 477,210 Pa.
  • Core 2 was a Styrene-Isoprene-Styrene Polymer (KRATON D 1161 P; from Kraton Polymers). Core 2 had a Tg of 215 K and a storage modulus of 240,120 Pa.
  • Core 3 was a pressure sensitive adhesive comprising a blend of 45 wt.% of a Styrene-Isoprene-Styrene Polymer (KRATON Dl 161P); 45 wt.% of a Aromatically Modified C-5 Hydrocarbon Resin (WINGTACK PLUS; from Sartomer); and 10 wt.% of a liquid polyterpene resin (SYLVARES TR A25; from Arizona Chemicals). Core 3 had a Tg of 259 K and a storage modulus of 68,764 Pa.
  • KRATON Dl 161P Styrene-Isoprene-Styrene Polymer
  • INDOPOL H-100 Liquid Polybutene
  • Core 5 was tackif ⁇ ed styrene-butadiene-styrene copolymer described as example CE6 in U.S. Patent Application No. 6,277,488 (Kobe, et al). Core 5 had a Tg of 260 K and a storage modulus of 90,710 Pa.
  • Skin 4 was a blend of 80 wt.% ethylene octene copolymer (EXACT 0201; from Exxon) and 20 wt.% Acid/Acrylate-modif ⁇ ed ethylene vinyl acetate (EVA) (BYNEL 3101; from Du
  • Examples 1-30 were prepared using various combinations of low and high modulus core and skin materials using a blown film process.
  • the core and skin layers were each fed to a three-layer, 5 cm (2 inch) annual die using 1.9 cm (0.75 inch) single screw BRABENDER extruders.
  • the tubular coextruded blown film was collapsed to form a flat tube approximately 15 cm (6 inch) wide. This construction was then wound on a paper core.
  • Comparative Example CEl was prepared using 19 mm (0.75 inch) BRABENDER (S. Hackensack, NJ) lab extruder with mixing screw. After melting and mixing, the extrudate was forced through a 15 cm (6 inch) flat cast extrusion die to form a molten film. The molten film was then passed through a chilled roll stack to cool and solidify the resins into final, finished film form.
  • BRABENDER S. Hackensack, NJ
  • Table 2a Multilayer flashing tapes with low tensile modulus polyolefm skins.
  • Table 2c Multilayer flashing tapes with high tensile modulus polyolefin skins.
  • Table 2d Multilayer flashing tapes with low and high tensile modulus hybrid skins.
  • Table 2e Multilayer flashing tapes with low and intermediate tensile modulus hybrid skins.
  • Table 2f Multilayer flashing tapes with high tensile modulus blended skins.
  • Table 2g Multilayer flashing tapes with intermediate modulus urethane skins.
  • Example 31 was prepared with an acrylic pressure sensitive adhesive core.
  • the core was a 76 micron thick layer of a cured monomer mixture containing 90 wt.% isooctyl acrylate and 10 wt.% acrylic acid.
  • Skin material S-I was hand-laminated as a 51 micron thick layer to opposite sides of the core. Following the Water Penetration Test procedure, ten out of twelve nails passed resulting in a board pass rate of 75% and a nail pass rate of 83%.
  • Examples 32 and 33 illustrate a construction with only a single skin layer.
  • Example 32 included a 152 micron thick layer of blended skin material S-4 hand- laminated to a 254 micron thick layer of Core 5.
  • Example 33 included a 178 micron thick layer of blended skin material S-4 hand-laminated to a 102 micron thick layer of Core 5.
  • Table 3 Water Penetration Test results for two-layer samples.
  • Comparative Example C-2 was a flashing tape made with DupontTM Tyvek®, an elastic material, a polyolefm film, and a highly adhesive butyl sealant (DuPontTM Flex WrapTM).
  • Comparative Example C-3 consisted of high performance cross-laminated polyethylene film and rubberized asphalt (Grace Vycor® Plus). Comparative Example C-3 is believed to be a butyl rubber PSA with a metal foil (Pella®SmartflashTM INSTALLATION TAPE).
  • Table 4 Water Penetration Test results for commercially available samples.
  • Example 34 was a three-layer construction adhered to a board as described above, except that no WRB was used.
  • the results of the Water Penetration Test are included in Table 5, and show that good results were achieved even without the use of the
  • Table 5 Water Penetration Test results for a sample prepared without a water resistive barrier.

Abstract

The present disclosure relates generally to a flashing tape used in construction applications to seal out moisture, and methods of using the same. The tape constructions disclosed include a viscoelastic core layer and at least one elastomeric skin layer, and may further contain a layer of pressure sensitive adhesive to attach the flashing tape to a substrate.

Description

MULTILAYER FLASHING TAPE
FIELD
[0001] The present disclosure relates generally to a flashing tape used in construction applications to seal out moisture, and methods of using the same. The flashing tapes comprise a viscoelastic core and at least one elastomeric skin layer.
BACKGROUND
[0002] Many construction practices commonly require the installation of a self-adhered flashing tape over the fenestration joints i.e. the joint between penetrations (such as windows, doors, ventilation ducts, etc.) and the building structure as well as on various surfaces adjacent to or within the fenestration to seal out water. These flashing tapes are installed prior to installation of the siding or trim. Nails used to attach the siding or trim to the building structure are often installed right through the flashing tape.
SUMMARY
[0003] In one aspect, the present disclosure is directed to a multi-layer flashing tape, the tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer.
[0004] In some embodiments, the second elastomeric skin layer may be eliminated such that the core layer of the construction is attached to a substrate with the single skin layer outwardly exposed.
[0005] In some embodiments, at least a portion of the exposed surface of either the first and/or second elastomeric skin layer may be coated with a pressure sensitive adhesive (PSA) to assist in the attachment of the film to a substrate. In those embodiments where the second skin layer is eliminated, a PSA may be applied to at least a portion of the core layer to assist in the attachment of the film to a substrate. [0006] In another aspect, the present disclosure is directed to a method of sealing a fenestration, the method comprising the steps of:
(i) providing a multi-layer flashing tape, the tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and optionally a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer; and
(ii) adhering the multi-layer flashing tape to the fenestration joints and surfaces adjacent to or within the fenestration.
[0007] In yet another aspect, the present disclosure is directed to a method of sealing an intersection between buildings surfaces, for example, a roof-wall joint, a roof valley, a roof peak, etc., wherein the method comprises the steps of:
(i) providing a multi-layer flashing tape, the tape comprising a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer; and optionally a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer; and
(ii) adhering the multi-layer flashing tape to the surfaces.
[0008] As used herein, the term "viscoelastic" means the characteristic of a material that has both viscous and elastic mechanical properties. Viscous materials tend to deform or flow under an applied stress. Elastic materials tend to recover or rebound after an applied stress is removed. As used to describe the materials herein, the term "viscoelastic" refers to materials having a G' Storage Modulus of about 30,000 Pa to about 500,000 Pa.
[0009] As used herein, the term "elastomeric" means the characteristic of a material that is both flexible and elastic. These materials tend to recover or rebound after an applied stress is removed. As used to describe the materials herein, the term "elastomeric" refers to materials having an elastic recovery of greater than about 70%.
[0010] As used herein, the term "fenestration" means any opening in a buildings envelope for the placement of windows, doors, skylights, ventilation ducts, chimneys and the like. [0011] As used herein, the term "thermoplastic material" means a material which softens or can be fused together when heated and which will harden again upon cooling. This process can be repeated many times with minimal degradation of physical or material properties.
[0012] As used herein, the term "pressure sensitive adhesive" or "PSA" means an adhesive that remains tacky after curing, coating or setting and which can firmly adhere to a variety of dissimilar surfaces upon contact without the need of anything more than finger or hand pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGURE illustrates a multilayer film according to some embodiments of the present disclosure.
DETAILED DESCRIPTION
[0014] The present disclosure is directed to a self-sealing, multilayered film that may be used in conjunction with a pressure-sensitive adhesive (PSA) as part of a flashing tape designed for sealing around mechanical fasteners such as nails to prevent water penetration in a building structure. In some embodiments, the multi-layered film structure comprises a viscoelastic core layer having a first major surface opposite a second major surface, a first elastomeric skin layer bonded to the first major surface of the core layer, and an optional second elastomeric skin layer bonded to the second major surface of the core layer.
[0015] In some embodiments, the multilayered films of the current disclosure advantageously provide excellent sealing properties in a material having a thin construction relative to known materials. Typical flashing materials utilize a relatively thick layer of butyl rubber or asphaltic adhesive applied to a carrier film layer. Such constructions have been known to fail at low temperatures and additionally add substantial thickness when applied to a fenestration joint. When flashing materials are too thick, windows, trim, siding, j-channel or other structures which must be installed into or adjacent to the fenestrations may not fit properly. [0016] In some embodiments, the multilayered film flashing materials described herein provide excellent sealing properties while having a total thickness of no greater than about 410 microns (e.g., no greater than about 380 microns) exclusive of the PSA adhesive. When applied to a fenestration joint or other surface, the flashing materials described herein protect structures from moisture penetration, even when punctured by nails, staples or other materials.
[0017] In one embodiment, the core layer has a thickness of no greater than about 127 microns. In a further embodiment, the core layer has a thickness that is no greater than about 80 microns, and in yet a further embodiment, the core layer thickness is no greater than about 55 microns.
[0018] In some embodiments, the core to skin ratio of the multilayered film is at least 0.2, e.g., at least about 0.5. In some embodiments, the core to skin ratio of the multilayered film is no greater than 5, e.g., no greater than 2.5. In some embodiments, the core to skin ratio of the multilayered film ranges from about 0.2 to about 5. In other embodiments, the core to skin ratio of the multilayered film is ranges from about 0.5 to about 2.5.
[0019] While not wishing to be bound by theory, the effectiveness of the multilayer film construction for sealing out water is dependent on both the type of skins and cores being utilized. For example, films constructed with skins that had higher elastic recovery (e.g., 96%) tended to perform better with cores that had a higher elasticity as shown by a higher G' Storage Modulus. Films constructed with skins that had lower elastic recovery (e.g., 73 to 75%) tended to work better with cores that were more deformable as shown by a lower G' Storage Modulus. It has generally been found that films with a high elastic recovery are harder to deform than films with a lower elastic recovery. Films constructed with skins that had a more intermediate level of elastic recovery (e.g., 79% to 90%) tended to perform better with a broader range of core materials. It should be noted that film samples that did not contain the core layer (as demonstrated by the Control Sample listed in the Examples) performed poorly, and that the addition of the viscoelastic core layer significantly and unexpectedly improved the performance of the film.
[0020] Core Layer [0021] The core layer may be made from a variety of viscoelastic materials. Non- limiting examples of materials which may be used for the core layer, either alone or in combination, include but are not limited to tackifϊed natural rubbers; synthetic rubbers such as butyl rubber; and tackifϊed linear and radial styrene block copolymers, such as styrene-butadiene, styrene-ethylene/butylene and styrene-isoprene; polyurethanes; polyvinyl ethers; acrylics, especially those having long chain alkyl groups; poly-alpha- olefϊns; asphaltics and silicones.
[0022] In one embodiment, a composition that is useful as a PSA for box sealing tape, comprising block or random styrene elastomers and tackifϊers is used. In another embodiment, the core layer can also be made from a block or random styrene elastomer copolymer resin without tackifϊer.
[0023] In some embodiments, the viscoelastic core layer has a storage modulus of from 30,000 Pa to 500,000 Pa. In some embodiments, the core has a storage modulus of no greater than 100,000 Pa, e.g., no greater than 75,000 Pa. In some embodiments, the core has a storage modulus at least 200,000 Pa, e.g., at least 400,000 Pa. In some embodiments, the viscoelastic core layer has a Glass Transition Temperature of from 200 K to 260 K.
[0024] Skin Layer(s)
[0025] Examples of elastomeric materials which can be utilized in the first or second skin layers include thermoplastic film forming polymers. Exemplary thermoplastic film forming polymers either alone or in combination include but are not limited to polyolefms (linear or branched), olefin block copolymers, polyamides, polystyrenes, polystyrene- butadienes, nylons, polyesters, polyester copolymers, polyurethanes, polysulfones, polyvinylidene chloride, styrene-maleic anhydride copolymers, styrene acrylonitrile copolymers, ionomers based on sodium or zinc salts of ethylene methacrylic acid, polymethylmethacrylates, cellulosics, fluoroplastics, acrylic polymers and copolymers, polycarbonates, polyacrylonitriles, ethylene -vinyl acetate copolymers, and mixtures thereof.
[0026] In some embodiments, at least one skin layer, in some embodiments both skin layers, have a tensile modulus of no greater than 8 MPa, e.g., no greater than 5 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have a tensile modulus of between 10 and 20 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have a tensile modulus of at least 30 MPa, e.g., at least 40 MPa. In some embodiments, at least one skin layer, in some embodiments both skin layers, have an elastic recovery of at least 70%, in some embodiments, at least 90%, or even at least 95%.
[0027] In some embodiments, the construction includes a core layer having a storage modulus at least 200,000 Pa, e.g., at least 400,000 Pa, and at least one skin layer (in some embodiments, both skin layers) having a tensile modulus of no greater than 8 MPa, e.g., no greater than 5 MPa. In some embodiments, the construction includes a core layer having a storage modulus no greater than 100,000 Pa, e.g., no greater than 75,000 Pa, and at least one skin layer (in some embodiments, both skin layers) having a tensile modulus of at least 30 MPa, e.g., at least 40 MPa.
[0028] PSA Layer
[0029] In an embodiment where either one or two skin layers are used, a PSA layer may be applied to at least a portion of the exposed surface of one or both skin layers, or to the underside of the core layer, in order to facilitate attachment of the core or skin layer to the substrate or joint to be protected. Suitable materials which may be utilized for the PSA layer, either alone or in combination, include, but are not limited to tackifϊed natural rubbers; synthetic rubbers such as butyl rubber; and tackifϊed linear and radial styrene block copolymers, such as styrene -butadiene, styrene-ethylene/butylene and styrene- isoprene; polyurethanes; polyvinyl ethers; acrylics, especially those having long chain alkyl groups; poly-alpha-olefϊns; asphaltics and silicones.
[0030] In one embodiment, an acrylic PSA that offers low temperature adhesion performance is used. The PSA layer should have sufficient adhesive strength to adhere the flashing material to a building structure comprising materials such as wood, polyvinyl chloride, rigid polystyrene foamboard, polymer materials used in housewrap applications, concrete block, poured concrete, building paper, and the like. The PSA layer may be applied with full or partial coverage on one or both of the skin layers, or the core layer in the embodiment where only one skin layer is used. [0031] The PSA layer may be applied to the multilayer film structure by extrusion, lamination or other conventionally known methods. A release liner may be applied over the adhesive to protect the adhesive until the multilayer flashing film is ready for use.
[0032] Additional Additives
[0033] The core layer and/or the skin layers may also contain other components such as pigments, fillers, ultraviolet absorbing agents, light stabilizers (e.g., hindered amine light stabilizers), slip agents, antiblocking agents, antistatic agents, processing aids, and carrier resins for additives, all of which are familiar to those skilled in the art. These additives are preferably chosen so as not to interfere with the desired performance and physical, chemical and adhesive properties of the film construction.
[0034] An exemplary multilayer film according to some embodiments of the present disclosure is shown in the Figure. Multilayer film 10 includes core layer 20 and first skin layer 31 on one major surface of the core layer. In some embodiments, second skin layer 32 is located on the opposite major surface of core layer 20. In some embodiments, a tape, e.g., a flashing tape, can be prepared by including optional adhesive layer 40, which is shown adjacent second skin layer 32 in the Figure.
[0035] The multilayer films of the present disclosure may be formed by any convenient layer forming process such as coating, lamination, co-extruding layers or stepwise extrusion of layers. Co-extrusion per se is well-known. The individual layers are typically coextruded through a specialized feed block or a specialized die that will bring the diverse materials into contact while forming the film.
[0036] Co-extrusion may be carried out with multilayer feed blocks or dies, for example, a three-layer feed block (fed to a die) or a three-layer die such as those made by Cloeren Co., Orange, Texas. Typically, streams of materials flowing out of extruders at different viscosities are separately introduced into the feedblock and converge to form a film.
[0037] The feed block and die used are typically heated to facilitate polymer flow and layer adhesion. The temperature of the die depends on the polymers used. Whether the film is prepared by coating, lamination, sequential extrusion, co-extrusion, or a combination thereof, the film formed and its layers will preferably have substantially uniform thicknesses across the film.
[0038] Flashing materials made with the multi-layer films as described herein may be wound onto cores and packaged in roll-form, in any size that is convenient for covering various fenestration joints or other related surfaces. In use, the flashing material is installed onto various building surfaces so that a path for draining incidental water is provided.
[0039] As used herein and in the appended claims, the singular forms "a," "and," and "the" include plural referents unless the context clearly dictates otherwise. Unless otherwise indicated, all numbers expressing chemical, physical or other properties in the specification and claims are to be understood as being modified by the term "about" in all instances. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[0040] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0041] Illustrative embodiments of the disclosure are discussed and reference has been made to possible variations within the scope of this disclosure. These and other variations and modifications in the disclosure will be apparent to those skilled in the art without departing from the scope of the disclosure, and it should be understood that this disclosure is not limited to the illustrative embodiments set forth herein.
Examples
[0042] I. Water Penetration [0043] The testing was conducted using a water spray booth in accordance with the International Code Council (ICC) Acceptance Criteria for Flexible Flashing Materials (AC- 148) and the American Architectural Manufacturers Association document AAMA 711. The test method listed in AAMA 711 Annex 1 is a modified version of ASTM E331. Note: The test method requires 3 sample boards run simultaneously at an air pressure of 5 inches of water (1.25 kPa) and 3 sample boards run simultaneously at an air pressure of 1.57 inches of water (0.39 kPa). For most of these examples, 4 sample boards (two at a time) at 5 inches of water pressure (1.25 kPa), were tested. The data is based on initial conditions only - no thermal cycling was performed. For some samples that performed very poorly, only two panels were tested.
[0044] Individual sample boards were prepared in accordance with AAMA 711 Annex 1, as generally follows. The required pattern of holes was drilled in a square plywood panel. A water resistive barrier (WRB) (Tyvek®, a spunbonded olefin film, available from Dupont™ Company) was applied over the holes and stapled to the board. Samples of the exemplary multilayer constructions were then adhered to the board over the WRB using 58 microns (2.3 mils) of 3M 300 LSE Pressure Sensitive Adhesive to adhere the samples during testing. Roofing nails approximately 3 mm (120 mils) in diameter were then driven through the test constructions and the WRB, and into the board. The resulting sample boards were then tested.
[0045] II. Mechanical Properties
[0046] Elastic Recovery was measured using a modified version of ASTM D5459 on 3 specimens taken from the machine direction at a width of 13 mm (0.5 inch). Tensile Modulus and 1% Secant Modulus were measured using a modified version of ASTM D882 on 3 specimens taken from the machine direction at a width of 13 mm (0.5 in.). Shear Storage Modulus (G') was measured on core samples C-I to C-4 using an RDA II rheometer from Rheometrics, Inc. at 1 Hz, 1% strain, at 21 0C (70 0F), 49% relative humidity, using 25 mm diameter parallel plates at 500 g compression. Shear Storage Modulus (G') for core sample C-5 was measured using an ARES rheometer from TA Instruments. The measurements were taken using 25 mm diameter parallel plates in dynamic mode with approximately 45O g compressive force at 1 Hz, 1% Strain, at approximately 24 0C (74 0F) [0047] The glass transition temperature (Tg) was calculated using the Fox equation. [0048] Core Materials.
[0049] Core 1 (C-I) was a Styrene-Ethylene/Butylene-Styrene Polymer (KRATON G1657; from Kraton Polymers). Core 1 had a Tg of 215 K and a storage modulus of 477,210 Pa.
[0050] Core 2 (C-2) was a Styrene-Isoprene-Styrene Polymer (KRATON D 1161 P; from Kraton Polymers). Core 2 had a Tg of 215 K and a storage modulus of 240,120 Pa.
[0051] Core 3 (C-3) was a pressure sensitive adhesive comprising a blend of 45 wt.% of a Styrene-Isoprene-Styrene Polymer (KRATON Dl 161P); 45 wt.% of a Aromatically Modified C-5 Hydrocarbon Resin (WINGTACK PLUS; from Sartomer); and 10 wt.% of a liquid polyterpene resin (SYLVARES TR A25; from Arizona Chemicals). Core 3 had a Tg of 259 K and a storage modulus of 68,764 Pa.
[0052] Core 4 (C-4) was a blend of 50 wt.% of a Styrene-Isoprene-Styrene Polymer (KRATON Dl 161P) and 50 wt.% of a Liquid Polybutene (MW=900) (INDOPOL H-100; from Ineos). Core 4 had a Tg of 208 K and a storage modulus of 35,016 Pa.
[0053] Core 5 (C-5) was tackifϊed styrene-butadiene-styrene copolymer described as example CE6 in U.S. Patent Application No. 6,277,488 (Kobe, et al). Core 5 had a Tg of 260 K and a storage modulus of 90,710 Pa.
[0054] Skin Materials
[0055] The properties of the various skin materials are summarized in Table 1. Skin 4 was a blend of 80 wt.% ethylene octene copolymer (EXACT 0201; from Exxon) and 20 wt.% Acid/Acrylate-modifϊed ethylene vinyl acetate (EVA) (BYNEL 3101; from Du
Pont).
Table 1 : Skin materials.
Figure imgf000011_0001
Figure imgf000012_0001
[0056] Examples 1-30 were prepared using various combinations of low and high modulus core and skin materials using a blown film process. The core and skin layers were each fed to a three-layer, 5 cm (2 inch) annual die using 1.9 cm (0.75 inch) single screw BRABENDER extruders. The tubular coextruded blown film was collapsed to form a flat tube approximately 15 cm (6 inch) wide. This construction was then wound on a paper core.
[0057] Comparative Example CEl was prepared using 19 mm (0.75 inch) BRABENDER (S. Hackensack, NJ) lab extruder with mixing screw. After melting and mixing, the extrudate was forced through a 15 cm (6 inch) flat cast extrusion die to form a molten film. The molten film was then passed through a chilled roll stack to cool and solidify the resins into final, finished film form.
[0058] The sample constructions and results are summarized in Tables 2a through 2g.
Table 2a: Multilayer flashing tapes with low tensile modulus polyolefm skins.
Figure imgf000012_0002
Figure imgf000013_0001
Table 2c: Multilayer flashing tapes with high tensile modulus polyolefin skins.
Figure imgf000013_0002
Table 2d: Multilayer flashing tapes with low and high tensile modulus hybrid skins.
Figure imgf000013_0003
Table 2e: Multilayer flashing tapes with low and intermediate tensile modulus hybrid skins.
Figure imgf000013_0004
Table 2f: Multilayer flashing tapes with high tensile modulus blended skins.
Figure imgf000013_0005
Table 2g: Multilayer flashing tapes with intermediate modulus urethane skins.
Figure imgf000014_0001
[0059] Example 31 was prepared with an acrylic pressure sensitive adhesive core. The core was a 76 micron thick layer of a cured monomer mixture containing 90 wt.% isooctyl acrylate and 10 wt.% acrylic acid. Skin material S-I was hand-laminated as a 51 micron thick layer to opposite sides of the core. Following the Water Penetration Test procedure, ten out of twelve nails passed resulting in a board pass rate of 75% and a nail pass rate of 83%.
[0060] Examples 32 and 33 illustrate a construction with only a single skin layer. Example 32 included a 152 micron thick layer of blended skin material S-4 hand- laminated to a 254 micron thick layer of Core 5. Example 33 included a 178 micron thick layer of blended skin material S-4 hand-laminated to a 102 micron thick layer of Core 5. The samples were subjected to the Water Penetration Test procedure. The results are summarized in Table 3. Table 3 : Water Penetration Test results for two-layer samples.
Figure imgf000014_0002
[0061] Three commercially available products were tested using the Water Penetration Test procedure. Comparative Example C-2 was a flashing tape made with Dupont™ Tyvek®, an elastic material, a polyolefm film, and a highly adhesive butyl sealant (DuPont™ Flex Wrap™). Comparative Example C-3 consisted of high performance cross-laminated polyethylene film and rubberized asphalt (Grace Vycor® Plus). Comparative Example C-3 is believed to be a butyl rubber PSA with a metal foil (Pella®Smartflash™ INSTALLATION TAPE). Table 4: Water Penetration Test results for commercially available samples.
Figure imgf000014_0003
Figure imgf000015_0001
[0062] Example 34 was a three-layer construction adhered to a board as described above, except that no WRB was used. The results of the Water Penetration Test are included in Table 5, and show that good results were achieved even without the use of the
WRB.
Table 5 : Water Penetration Test results for a sample prepared without a water resistive barrier.
Figure imgf000015_0002
[0063] Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention.

Claims

What is claimed is:
1. A multilayer film comprising: a viscoelastic core layer having a first major surface opposite a second major surface, and a core layer thickness; and a first elastomeric skin having a first skin thickness bonded to the first major surface of the core layer.
2. The multilayer film of claim 1, further comprising a second elastomeric skin having a second skin thickness bonded to the second major surface of the core layer.
3. The multilayer film of claim 2, wherein a first ratio of the core layer thickness to the first skin thickness and a second ratio of the core layer thickness to the second skin layer thickness are each no greater than 5.
4. The multilayer film of claim 2 or 3, wherein both the first ratio and the second ratio are at least 0.2.
5. The multilayer film according to any one of the preceding claims, wherein the viscoelastic core layer has a storage modulus of from 30,000 Pa to 500,000 Pa.
6. The multilayer film of claim 5, wherein the viscoelastic core layer has a storage modulus of no greater than 100,000 Pa.
7. The multilayer film of claim 5, wherein the viscoelastic core layer has a storage modulus of at least 200,000 Pa.
8. The multilayer film according to any one of the preceding claims, wherein the core layer thickness is no greater than 127 microns.
9. The multilayer film according to any one of the preceding claims, wherein the first skin thickness and the second skin thickness are each no greater than 127 microns.
10. The multilayer film according to any one of the preceding claims, wherein at least one skin layer has a tensile modulus of no greater than 8 MPa.
11. The multilayer film according to any one of claim 1 to 9, wherein at least one skin layer has a tensile modulus of between 10 and 20 MPa.
12. The multilayer film according to any one of claim 1 to 9, wherein at least one skin layer has a tensile modulus of at least 30 MPa.
13. The multilayer film according to any one of claim 1 to 9, wherein the core layer has a storage modulus at least 200,000 Pa, and at least one skin layer has a tensile modulus of no greater than 8 MPa.
14. The multilayer film according to any one of claim 1 to 9, wherein the core layer has a storage modulus no greater than 100,000 Pa, and at least one skin layer having a tensile modulus of at least 30 MPa.
15. The multilayer film according to any one of the preceding claims, wherein at least one skin layer has an elastic recovery of greater than 90%.
16. The multilayer film according to any one of the preceding claims, wherein viscoelastic core and the first skin layer comprise a thermoplastic material.
17. The multilayer film according to any one of the preceding claims, further comprising an adhesive layer on at least a portion of one or more of the first skin layer, the second skin layer, and the core layer.
18. The multilayer film according to any one of the preceding claims, wherein the film is self-sealing as indicated by an 80% nail pass rate based on the Modified ASTM E331 Spray Booth Test.
19. A method of sealing a surface, the method comprising the steps of:
(i) providing the multilayer film according to any one of the preceding claims; and
(ii) adhering the multilayer film to the surface.
20. The method of claim 19, wherein the surface is a fenestration surface.
21. The method of claim 20, wherein the surface comprises the intersection between buildings surfaces, optionally wherein the building surfaces are selected from the group consisting of a roof- wall joint, a roof valley, a wall-to-wall joint, ledger-board wall joints, the joint between the underside of a roof and the adjacent wall, and a roof peak.
PCT/US2008/087601 2007-12-21 2008-12-19 Multilayer flashing tape WO2009086056A2 (en)

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US12/808,820 US20100307658A1 (en) 2007-12-21 2008-12-19 Multilayer flashing tape
JP2010539855A JP5694777B2 (en) 2007-12-21 2008-12-19 Multi-layer flushing tape
CN2008801244044A CN101909884A (en) 2007-12-21 2008-12-19 Multilayer flashing tape
EP08869013A EP2231400B1 (en) 2007-12-21 2008-12-19 Multilayer flashing tape
US13/690,459 US20130139953A1 (en) 2007-12-21 2012-11-30 Multilayer Flashing Tape

Applications Claiming Priority (2)

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US1627207P 2007-12-21 2007-12-21
US61/016,272 2007-12-21

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KR (1) KR101568889B1 (en)
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JP5694777B2 (en) 2015-04-01
JP2011507736A (en) 2011-03-10
EP2231400A2 (en) 2010-09-29
KR101568889B1 (en) 2015-11-12
US20100307658A1 (en) 2010-12-09
CN103469904A (en) 2013-12-25
KR20100098544A (en) 2010-09-07
EP2231400A4 (en) 2011-01-19
US20130139953A1 (en) 2013-06-06
WO2009086056A3 (en) 2009-10-22
CN101909884A (en) 2010-12-08
EP2231400B1 (en) 2012-08-01

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